Air Bellows for Aerospace Applications: Precision and Efficiency

In the demanding field of aerospace, reliability and efficiency are paramount. Air bellows, also known as air springs, have emerged as indispensable components for achieving high-performance actuation and vibration isolation in aerospace applications. At Tevema, we have extensive experience in designing and manufacturing air springs tailored specifically to the aerospace industry’s unique needs. With a deep understanding of the specific challenges faced in aerospace engineering, we are committed to delivering products that enhance performance, safety, and durability.

The Role of Air Bellows in Aerospace Systems

Air bellows are integral to several key aerospace systems, providing vibration isolation and motion control. These elements are especially beneficial where lightweight and efficient shock absorption is required, such as in aircraft landing gear, actuation systems, and vibration control for avionics. Additionally, air bellows play an important role in managing dynamic forces during critical flight phases, offering stability where it is needed most.

Why Air Bellows Are Critical in Aerospace

The primary advantage of using air bellows in aerospace is their ability to absorb shock and isolate vibrations. This is particularly vital in an aircraft environment, where even minor vibrations can affect sensitive equipment or lead to fatigue in structural components. With more than 99% vibration isolation efficiency, Tevema’s air bellows ensure superior reliability. As Isaac Newton once said, “Truth is ever to be found in simplicity, and not in the multiplicity and confusion of things.” This simplicity and efficiency of air springs, which contain no sliding seals and therefore require no lubrication, aligns perfectly with Newton’s wisdom.

Another significant benefit is flexibility. Air bellows are compact and versatile, allowing integration into a wide variety of aerospace structures. They can be designed to work effectively across a range of temperatures, from -40°C to +115°C, which suits the challenging conditions often found in high-altitude and high-speed aerospace environments. Moreover, their resilience against extreme conditions makes them a practical choice for various functions, including actuation and isolation in unpredictable aerospace scenarios.

Design Considerations for Aerospace Air Bellows

We design our air bellows to meet the specific requirements of aerospace applications. The materials used, such as chlorobutyl rubber or EPDM, provide excellent resistance to oils, fuels, and extreme temperatures, making them ideal for aerospace use. Moreover, we offer customized versions that use high-strength four-ply construction to achieve pressure capabilities up to 12 bar, which are crucial for high-performance applications. This versatility in material selection ensures that the air bellows can be optimized to meet stringent safety and operational demands.

Structural Integration and Customization

Air bellows are often used in conjunction with auxiliary reservoirs to enhance their vibration isolation capabilities by reducing the system’s natural frequency. This flexibility is highly advantageous when designing aircraft, as it allows for improved comfort and safety without adding excessive weight. The bellows are available in different configurations:

• Single convolution for compact areas.
• Double and triple convolutions for enhanced load distribution and greater stroke requirements.

The modular nature of these designs ensures that air bellows can be tailored to specific force and stroke requirements. This adaptability is essential in aerospace, where every component must perform optimally within space and weight constraints. By customizing the structural integration, our engineers ensure that each air bellow application maximizes efficiency, thus contributing to both the performance and longevity of the aircraft systems.

Furthermore, Tevema’s air bellows can be integrated into systems that require fail-safe mechanisms. Their ability to accommodate angular misalignment and tolerate lateral forces ensures a robust and adaptable solution, even in highly dynamic environments. This adaptability allows for a reduction in component wear and tear, ultimately extending the lifespan of the aerospace systems they are part of.

Key Applications of Air Bellows in Aerospace

1. Landing Gear Suspension SystemsTevema’s air bellows are often used in landing gear systems to provide shock absorption during take-off and landing. The bellows’ ability to handle high loads and rapid stroke response ensures passenger comfort and minimizes stress on the aircraft structure. The precise control of damping and shock absorption provided by air bellows helps to distribute impact forces evenly, reducing the risk of structural damage during hard landings or rough terrain operations.
2. Vibration Isolation for AvionicsAvionics equipment is particularly sensitive to vibrations. Air bellows help isolate these systems, ensuring consistent performance even during turbulence or extreme maneuvers. By maintaining a constant natural frequency irrespective of the load, air springs offer stability that standard metal springs cannot achieve. This stability is critical for avionics components, which must function flawlessly for navigation, communication, and control, all of which are vital for ensuring flight safety and efficiency.
3. Actuation SystemsAir bellows also serve as actuators for various aircraft components. They are lightweight and eliminate the need for complex hydraulic or pneumatic cylinders, reducing overall system weight and maintenance requirements. The simplicity of air bellow-based actuation systems helps streamline aircraft maintenance schedules and reduces the likelihood of system failures. As Albert Einstein once remarked, “Strive not to be a success, but rather to be of value.” Tevema’s air bellows embody this philosophy by delivering exceptional value through simplicity and reliability, while offering dependable actuation for complex aerospace mechanisms.
4. Passenger and Cargo Comfort SystemsAir bellows are also employed in cabin comfort systems to enhance passenger experience. By isolating seats and internal components from aircraft vibrations, they provide a smoother ride, minimizing fatigue for passengers. Similarly, in cargo holds, air bellows are used to cushion sensitive cargo from vibration and sudden movements, ensuring safe and secure transit.

Advantages of Tevema Air Bellows for Aerospace

1. Enhanced Vibration Isolation

Our air bellows are designed to offer unsurpassed vibration isolation. By maintaining a low natural frequency (as low as 1 Hz), they outperform traditional coil springs in aerospace settings, where consistent isolation is crucial for onboard electronics and structural integrity. This capability to maintain low natural frequency across different load conditions significantly reduces fatigue, thereby increasing the lifespan of critical aircraft components.

2. No Maintenance Required

Unlike traditional hydraulic actuators, Tevema’s air bellows have no internal seals that are susceptible to wear, meaning they require zero maintenance. This contributes to reduced downtime and operational costs—key considerations for aerospace operators. The factory-sealed units are tested rigorously before shipment, ensuring reliable performance throughout their service life. This maintenance-free operation is particularly valuable in aerospace, where reducing unexpected maintenance events is a priority.

3. Operational Flexibility

Our bellows can operate with compressed air, nitrogen, or even water in some applications, depending on the requirements. This versatility enables the use of air bellows in a wide variety of aerospace systems, providing designers the flexibility to solve complex problems without resorting to multiple component types. In addition, the air bellows’ compatibility with varied working media makes them a great choice for hybrid systems, where multiple functions are combined to optimize space and weight efficiency.

4. Compact and Lightweight Design

Space and weight are always at a premium in aerospace engineering. The compact and lightweight design of Tevema’s air bellows makes them an ideal choice for applications where weight savings translate directly into improved fuel efficiency and range. Additionally, their low installed height allows them to fit into areas where conventional spring systems would be impractical.

Choosing the Right Air Bellows for Aerospace

When selecting an air bellow, several factors must be considered:

• Load Capacity: The expected load range must match the capabilities of the bellow.
• Stroke Length: Different aircraft applications demand specific stroke lengths.
• Operating Environment: Temperature and potential exposure to corrosive substances are important design considerations.
• Installation Height: Compact designs are preferred, especially in areas with stringent space limitations.

Tevema offers a range of solutions that cater to these diverse needs, including configurations with crimped plates for increased robustness or bead ring designs for flexibility in installation and maintenance. Our expertise allows us to tailor each bellow to suit unique requirements, ensuring maximum efficiency and reliability.

Integration with Auxiliary Reservoirs

Adding an auxiliary reservoir can significantly enhance the performance of air bellows by increasing the system’s effective air volume, thereby reducing the system’s natural frequency. This feature makes them ideal for applications such as cargo isolation, where the reduction of vibration and noise is a high priority. The use of auxiliary reservoirs also provides a smoother, more controlled response, which can be crucial in maintaining stability during critical flight operations. Auxiliary reservoirs also enhance the adaptability of air bellows, allowing them to handle varying load conditions without compromising performance.

Air bellows are an invaluable component in aerospace applications, offering a combination of vibration isolation, shock absorption, and actuation capabilities. At Tevema, we leverage our expertise to provide high-performance air springs that cater to the demanding needs of the aerospace industry. From landing gear to avionics protection, our air bellows deliver unmatched reliability and performance.

The aerospace sector continuously strives for efficiency and safety, and we at Tevema are proud to contribute with our specialized air bellows solutions, helping our clients overcome challenges and enhance their systems’ performance. Whether you are looking for shock absorption solutions, vibration control for avionics, or innovative actuation mechanisms, our air bellows offer a reliable, cost-effective solution that meets the exacting demands of modern aerospace engineering. We look forward to partnering with you to elevate aerospace performance to new heights.